An Experimental Investigation of Industrial Gearbox Condition Using Wear Particle Analysis Technique

In different lubricated machines as engines and gearboxes, the generated wear particles analysis is considered as an effective tool for condition monitoring of these machines. Wear particle analysis as a nondestructive evaluation technique is an effective method to determine the lubricating oil conditions within different lubricated machines, thus monitoring wear modes and imminent failures in these machines. Machine condition monitoring is a cost-effective and reliable system to predict mechanical behavior and efficiency of power plant systems. Qualitative, quantitative and morphological data could be obtained from the wear particle analysis through the periodically taken samples of the lubricant. Different methods are used to detect and analyze wear debris in the lubricant oil, such as ferrograhy, spectrometry, filtergram, particle counters and recently Laser oil analyzer and time-dependent limits monitor factors. The objective of the present work is to apply wear particle analysis technique for condition monitoring of an industrial gearbox transmission over one year period. This transmission belongs to one of the largest carpet manufacturing plant in the world. The chosen gearbox for condition monitoring was a new gearbox installed to the rug textile machine. The gearbox components are elasto-hydrodynamically lubricated with mineral-based oil. The function of the gearbox is to drive the motion (forward and backward) of the knife to cut the fibbers of the carpet during the operation. Periodic oil samples were taken and analyzed through spectrometric technique while selective samples were chosen to be analyzed through ferrography technique. Spectrometric and ferrographic analysis were used where quantitative and qualitative changes in the concentration and size distribution of different particles were analyzed and compared to baseline and limit values. In addition to the sampling process, the gearbox performance was also monitored through measuring the oil temperature that was recorded just after the oil sample intake. The oil temperature is an indication for the gearbox loading which in its turn indicates any failure if it occurs. Results were analyzed, discussed and correlated to the gearbox performance. Also, recommendations were given for better performance based on the investigation and justification of the relevant results.